WARM ALL. Installation Guide Mesh Floor Heating System

Transcription

1 Installation Guide Mesh Floor Heating System

2 119A Sir Wilfrid Laurier Saint-Basile-le-Grand, (Québec), J3N 1M2 Tel: Toll Free: Fax:

3 This guide describes the WarmAll Mesh Floor Heating System how to design the room, and install the system. It is important to review this guide and the WarmAll Thermostat Installation and Operation Manual prior to installation. For additional information regarding any aspect of the mesh floor system, contact WarmAll. General Information The safety and reliability of any floor heating system depends upon proper design, installation and testing. The guidelines and instructions contained in this guide are important. The Mesh Floor Heating System is only designed for under floor heating purposes. The floor heating system must be installed by qualified professionals familiar with the proper sizing, installation, construction and operation of floor heating systems and the hazards involved. The installation of the equipment must comply with all national and/or local electrical codes. This product must be installed by a qualified person in accordance with this installation handbook and with the Canadian Electric Code Part I (Canada) or the National Electric Code (U.S.) as applicable. All electric connections must be made by a qualified electrician, according to the electrical and building codes effective in your region. WARNING: Shock and fire hazard If the Mesh is not installed properly and/or damaged, fire or shock can occur and can result in serious personal injury and/or damage to property. 25 Year Limited Warranty WarmAll warrants the heating mesh for a period of 25 years. The limited warranty is valid based on correct installation methods and completion of all test requirements.see WarmAll 3MWF Warranty for complete details. Safeguards and Warnings If the cable is damaged, it must be replaced. Do not attempt to splice or repair any part of the cable; Heating cable must be at least 15 cm (6 in) away from any heat source; 1 Only install cables above 40 degrees Fahrenheit or 5 degrees Celsius; Never energize the Mesh while it is still rolled-up; This cable must be grounded; Never install a cable designed for a 120 V power source on a 208/240 V power source; Do not install product if the packaging seal on the box has been broken; The Mesh system must not extend beyond the room or area in which it originates; The Mesh should be installed at a minimum distance of 2 inches from the base of a counter; The Mesh should be installed at a minimum distance of 2 inches from any walls; The Mesh should be installed at a minimum distance of 6 inches from any type of drain; The cable cannot be overlapped, cut or modified; All the heating portion of the cable (including the joint) must be fixed to the floor and covered with thin-set mortar; The heating cable should never be installed in/on walls; The system must not be installed under fixed furniture where air does not flow; The cable should never be installed over an expansion joint. IMPORTANT Remember to measure the resistance four times during the installation Remember to always measure, verify and record the actual resistance throughout the installation process. Recordings are taken when the cable is taken out of the box, after installation on sub-floor, after covering the cable with mortar, and after installation of final floor covering. WarmAll Mesh System: Specifications Cable construction: Rated voltage: Output: Heating element size: Bending radius: Cable diameter: Conductor insulation: Outer insulation: Max. ambient temp.: Min. installation temp.: Cold lead:n: twin conductor 120V, 240V 3W/ft (9.84W/m) ±10% 40 ft to 800 ft (12.2 to m) 1 in (25.4 mm) 1/8 to 1/6 in (3.2 to 4.2 mm) fluoropolymer fluoropolymer or TPE or nylon 85 F (30 C) 40 F (5 C) 2-wire 16 AWG plus ground braid; 10 ft (3 m) length 2

4 The design of the installation is required to achieve the intended floor heat system specification. All WarmAll Mesh Floor Heating Systems are spaced 3 inches apart, and are available for either 120V or 240V supply voltage. Measure and calculate the heated area of the floor where there are no permanent fixtures or furniture (such as showers, toilets, vanities, or cabinetry). For example, in Figure 3, the area of the bathroom is 96 ft2. When you subtract the area of the vanity, shower and toilet, the total heated area is 74 ft2. Plan the Design Existing ceramic; refer to the mortar manufacturer regarding proper floor preparation Acoustic membrane; Scratch coat; Anti-fracture membrane; Sand coat; Plan the Design The design of the installation is required to achieve the intended floor heat system specification. It is possible to install a 240V cable on a 208V circuit. Power loss will be about 25%. Measure and calculate the heated area of the floor where there are no permanent fixtures or furniture such as showers, toilets, vanities, or cabinetry. For example, the area of the bathroom is 96 ft2. When you subtract the area of the vanity, shower and toilet, the total heated area is 74 ft2. With all specifications determined and total heat area calculated, select the required Mesh. Models on 120V Ohms Thickness Watts Amps (mm) 20 Width 30 Width 3MWA - 120V Sq\Ft - 20''x 6,1' 10Pi/Ca-30''x4' 3MWA- 120V Sq\Ft - 20''x 9,1' 15Pi/Ca-30''x6' 3MWA - 120V Sq\Ft - 20''x12,2' 20Pi/Ca-30''x8' Floor Surface Preparation 3MWA - 120V MWA - 120V Sq\Ft - 20''x15,2' 30 Sq\Ft - 20''x 8,3' 25Pi/Ca-30''x10' 30Pi/Ca-30''x12' The subfloor must meet all construction standards relevant to the floor covering and the use a floor heating system. Verify with the sub-floor manufacturer for computability with a floor heating system. The floor must be clean, flat and clear of all debris, nails, screws Verify that the sub-floor is compatible with the thin-set mortar or the self-leveling underlayment that will be use during the installation. 3MWA - 120V MWA - 120V MWA - 120V MWA - 120V MWA - 120V Sq\Ft - 20''x 21,3' 40 Sq\Ft - 20''x 24,4' 50 Sq\Ft - 20''x 30,5' 60 Sq\Ft - 20''x 36,6' 70 Sq\Ft - 20''x 42,7' 35Pi/Ca-30''x14' 40Pi/Ca-30''x16' 50Pi/Ca-30''x20' 60Pi/Ca-30''x24' 70Pi/Ca-30''x28' Sub-floor compatibility Plywood Cement board Poured concrete slab on an existing floor Structural concrete slabs 3MWA - 120V MWA - 120V MWA - 120V Sq\Ft - 20''x 48,8' 90 Sq\Ft - 20''x 54,9' 100 Sq\Ft - 20''x 61,0' 80Pi/Ca-30''x32' 90Pi/Ca-30''x36' 100Pi/Ca-30''x40'

5 Models on 240V Ohms Watts Amps Thickness (mm) Width Width 3MWA - 240V Sq\Ft - 20''x12,2' 20Pi/Ca-30''x8' 3MWA - 240V Sq\Ft - 20''x18,3' 30Pi/Ca-30''x12' 3MWA - 240V Sq\Ft - 20''x21,3' 35Pi/Ca-30''x14' 3MWA - 240V Sq\Ft - 20''x24,4' 40Pi/Ca-30''x16' 3MWA - 240V Sq\Ft - 20''x30,5' 50Pi/Ca-30''x20' 3MWA - 240V Sq\Ft - 20''x36,6' 60Pi/Ca-30''x24' 3MWA - 240V Sq\Ft - 20''x42,7' 70Pi/Ca-30''x28' 3MWA - 240V Sq\Ft - 20''x48,8' 80Pi/Ca-30''x32' Determine the optimum floor layout with the help of WarmAll layout chart for the heated area to ensure adequate coverage. Select a spot for the thermostat in the wall above the heated area where it can be reached by the 10-ft cold lead on the cable and the 15-ft floor temperature sensor. It is recommended to leave a minimum of 2 inches between the perimeter walls and the edge of Mesh. 3MWA - 240V MWA - 240V MWA - 240V MWA - 240V MWA - 240V MWA - 240V IMPORTANT: 53.3 Confirm that your Mesh system is not bigger than the heated area before breaking product seal. N.B.: The floor sensor is in the thermostat box Sq\Ft - 20''x54,9' 100 Sq\Ft - 20''x61,0' 110 Sq\Ft - 20''x67,1' 120 Sq\Ft - 20''x73,2' 145 Sq\Ft - 20''x88,4' Sq\Ft - 20''x97,5' 90Pi/Ca-30''x36' 100Pi/Ca-30''x40' 110Pi/Ca-30''x44' 120Pi/Ca-30''x48' 145Pi/Ca-30''x58' 160Pi/Ca-30''x64' The floor probe (sensor) has to be installed directly between two cables. Fix the head of the sensor with hot glue or tape. The sensor should be installed at least 16 inches (30 cm) inside the heating area. Do not cross the sensor wire over the heating wire. The sensor should be installed away from any heating source other than the heating cable. Figure 4: Typical cold lead and floor temperature sensor Floor Sensor IMPORTANT: Perform all mandatory resistance tests described in this guide and follow all instructions in the limited warranty. Before removing the plastic that covers the cable on the spool the cable insulation and resistance should be verified and compared to the factory testing to ensure the cable is intact. Factory test data is on the grey tag at one end of the cold lead cable. Results should be similar to the factory results. If there is more than a 10% difference, call WarmAll. You must perform the Insulation Resistance Test, the Heating Cable Resistance Test, and the Sensor Resistance Test (the floor sensor is in the thermostat box) during the installation process. 5 6

6 Use an appropriate multimeter to measure the resistance between the black leads. If an automatic multimeter is used the reading will be taken instantly. If the multimeter is not automatic, set it to 200 Ω for a cable under 200 Ω or at the higher value for a cable over 200 Ω. Write the results on the warranty card. Electrical Circuit This floor heating system should be on a dedicated heating circuit. The maximum load of our thermostat is 15 Amps on 120V & 240V. If the installation requires more than 15 Amps, you can add an expansion unit (power unit) or a second thermostat. The current drawn by the cable (amps) is indicated on the cable tag. Important: Only connect the thermostat and the electrical power once the cable system has been installed and covered with the proper floor covering. Cold Lead Mark the position of the connection point between the power lead and the black heating cable. When using a floor-temperature-sensing thermostat, mark the sensor position in the middle of two heating mats or two heating cables in a mesh, about 10 in (25 cm) away from the wall (within the heated area), as close as possible to the thermostat. 2 PREPARE SUB-FLOOR SURFACE Clean and vacuum the sub-floor to remove dust and debris. Assure no nails, screws, or similar devices are protruding through the sub-floor as this can cause damage to the cables during installation. Also ensure that the sub-floor is stable and suitable to meet the construction standards of the final intended floor surface. The cold lead is the non-heating part of the cable system. It is joined to the heating cable by a heavy duty mechanical shrink. The mechanical joint must be installed on the floor and covered with thin-set mortar. It is possible to groove in the sub-floor to install the mechanical joint. 1 TRANSFER LAYOUT TO FLOOR Draw an outline of the layout on the floor including a footprint of all furnishings that are not yet installed. In accordance with the design, map out the mesh placement including all 90 degree turns or 180 degree flips to cover the required area. The starting point of the mesh must be placed within 10 ft from the thermostat. MESH INSTALLATION INSTRUCTIONS 7 8

7 WARNING: 3 MEASURE THE RESISTANCE OF THE CABLES (FIRST TIME) Test the resistance of the cable system prior to unrolling the mesh and breaking the packaging seal. 4 LAY THE MESH After completing the first resistance tests and confirming that the cable is free of defects, unroll the first few feet of mesh so that the connection point and the temperature sensor are in their intended positions and bring the power lead cable to the electrical connection box. Begin laying the heating mesh according to the design, securing the self-adhesive side of the mesh directly to the sub-floor. Never cut or shorten the heating cable in the Mesh system. Do not expose the mesh to any mechanical stress. Avoid walking on the mesh area and the cables. Wear only shoes with soft soles. 5 MEASURE THE RESISTANCE OF THE CABLES (THE SECOND TIME) Test the resistance of the cable system after the mesh is properly laid and secured on the sub-floor. 6 MEASURE RESISTANCE OF TEMPERATURE SENSOR AND INSTALL If using a floor-temperature-sensing thermostat, measure the resistance and install either in conduit tube or directly to the subfloor after confirming the sensor is free of defects.warmall recommends that the sensor be installed in a conduit tube to allow the sensor to be easily The mesh has a sticky face which can be repositioned as needed. replaced in the unlikely event of failure. 9 10

8 The sensor must be installed at a minimum of 16 inches away from the wall towards the middle of the Mesh.If a conduit tube is used, the conduit tube must be partially countersunk into the subfloor. Cut a channel approximately 5/16 in deep 5/16 in wide in the floor from the wall. The sensor conduit must be centered between two mats or in the cable loop between two heating wires on a mesh. Duct tape or hot glue should be used to close the end of the conduit and hold the sensor conduit into the groove to prevent it from floating up when the mortar is poured. Duct tape or hot glue should be used to secure it to the subfloor if the sensor is installed directly in the mortar bed. IMPORTANT WarmAll recommends that the installation be documented with photos to note the location of connections and the sensor. 7 EMBED THE FLOOR HEATING MESH IN MORTAR Based on the selected installation of the floor covering (such as concrete, ceramic tiles, engineered wood, laminate, etc.), cover the installed heating mesh system including sensors and connections with an appropriate mortar thickness to obtain an even and level finish. WarmAll recommends to consult with the flooring manufacturer for any special or minimum requirements to assure the proper function of the floor system and floor heating cables.the floor preparation and installation must be in accordance with industry best practices and always in accordance to the manufacturer s instructions and recommendations. 8 MEASURE THE RESISTANCE (THE THIRD TIME) Test the resistance of the cable system after the cable is covered in mortar. WARNING: The system must not be turned on until the mortar has fully dried. A minimum of 4 weeks is recommended. Example of Typical Installations and Applications WARNING: The sensor conduit must never be laid directly over the heating cable

9 9 DIRECTLY ON PLYWOOD: 10 CONNECT THERMOSTAT AND POWER SUPPLY The thermostat can now be installed in accordance with the Thermostat Installation and As required, a professional must validate the minimum power supply requirement are installed and available to power the cable heating system. IMPORTANT Mark the appropriate circuit breaker reference label indicating which branch supplies the circuits to the cables. 11 RECORD INFORMATION AND AFFIX LABELS It is important for the installer to mail in the warranty test card with all recorded results immediately after installing the system. Failure to do so will void the manufacturer's warranty. A copy of the warranty card should be kept for your reference. 9 DIRECTLY ON CONCRETE: ENJOY THE COMFORT OF WARMALL The mesh floor heating system is ready to use. Mandatory Resistance Testing Requirements For the extended 25 year limited warranty to apply, you must perform the tests in this section, and follow all instructions noted in the Limited Warranty. You must perform the Insulation Resistance Test, the Heating Cable Resistance Test, and the Sensor Resistance Test during the installation process. Insulation Resistance Test This test ensures that the insulating jackets of the cable are not damaged. A low value indicates the cable has been damaged and must be replaced

10 1.Connect the ground wire to the black lead and both power wires to the red lead of the multimeter. 2.Make sure the meter reads open or OL. If you get a different reading, contact WarmAll at Record these readings on the warranty card. Heating Cable Resistance Test This test measures the resistance of the Cable and is used to determine circuit integrity. 1.Set your multimeter to the 200 or 2000 ohm range. 2.Connect the multimeter leads to the black and white cold lead wires. 3.Compare this resistance reading to the resistance specified in the Product Selection Table 1 or Table 2. The value should be within ±10%. If you get a different reading, contact WarmAll at Record these readings on the warranty card. Sensor Resistance Test This test measures the resistance of the floor sensor and is used to verify the sensor integrity. 1.Set your multimeter to the 200K ohm range. 2.Connect the mutimeter leads to the red and green lead wires. Troubleshooting Symptom Probable Causes Corrective Action Floor does not heat Floor warm all the time Floor not warm enough No voltage. Circuit breaker tripped. Ground-fault tripped in the thermostat.at Thermostat not turned on. Cable not connected to thermostat. Floor temperature sensor not connected.t. Faulty sensor. Clock not set correctly. Thermostat setting not set correctly. Check circuit breaker Ensure that there are not too many multi outlet assemblies (MOAs) or other appliances connected on the same circuit. The cable may require a dedicated circuit. See the Product Selection Table 1 or Table 2 in this manual. Refer to the Thermostat Installation and Refer to Thermostat Installation and Refer to Thermostat Installation and Refer to Thermostat Installation and Contact 3MWF at Refer to Thermostat Installation and Refer to Thermostat Installation and 3.Make sure the meter reads between 9-25K ohms. If you get a different reading, contact WarmAll at Record these readings on the warranty card. Installation instructions not available Download the latest version of the Floor Heating System Installation Manual from